Motor vehicle door with a passenger protection system

ABSTRACT

A motor vehicle door having a door inside part ( 19 ), a door outside part ( 20 ) and a supporting panel ( 3 ) which is connected in a tight-fitting manner to the door inside part ( 19 ). The supporting panel ( 3 ) is a structural part made of a reinforced plastic, extends essentially over the surface of the door and has an edge ( 30, 31, 32, 33 ) all the way around, a first frame plate ( 4 ) and a second frame plate ( 5 ) are connected to the edge of the supporting panel ( 3 ), said frame plates being folded profiles which extend along the vertical parts of the edge, the first limb ( 42, 55 ) being connected to the edge ( 30, 31 ) of the supporting panel ( 3 ), the door inside part ( 19 ) is a shell made of plastic with fitting surfaces ( 49, 83 ) to which the second limbs ( 43, 56 ) of the frame plates ( 4, 5 ) and the supporting panel ( 3 ) are fastened, and the door inside part ( 19 ) protrudes outward over the supporting panel ( 3 ) and forms a connecting flange ( 50, 63 ), the door outside part ( 20 ) is a skin which is fastened to the connecting flange ( 50, 63 ) by means of a fastener ( 59 ).

BACKGROUND OF THE INVENTION

The invention concerns a motor vehicle door, comprising a door insidepart, a door outside part and a supporting panel which is connected in atight-fitting manner to the door inside part. The door inside part anddoor outside part are conventional sheet-metal shells which also formthe window frame and to which the hinges, the door lock and optionally adoor stopper are fitted; the supporting panel bears the diverseassemblies, such as window guides and window openers, and recently alsohas been given the task of protecting the occupants during lateral andfrontal collisions. The relevant regulations are becoming ever stricter.Because of them, there is an increase, on the one hand, in the safetyrequirements but, on the other hand, the production costs have to drop.

DE 198 09 750 A1 discloses a motor vehicle door in which a very stiffsupporting panel is clamped between the two sheet-metal shells. Althoughsaid supporting panel provides very good protection against penetrationduring a lateral collision, its small degree of extension means that thedeformation distances are too small for effective retardation. Theclamping between the sheet-metal shells in the plane of the supportingpanel does not permit any effective sealing between the outer space ofthe door, in which the window is guided, and the inner space, in whichthe electrics are accommodated. The two sheet-metal shells are bulky andcomplex punched parts, the precisely fitting joining together of whichis difficult during assembly. A door constructed in this manner is stillheavy and cannot be used for different vehicle variants (for example,coupe and convertible). But this is precisely what is desirable forreducing costs.

DE 197 44 810 A1 discloses a motor vehicle door in which a frame modulecan be lowered from above into a door box comprising two sheet-metalshells. The frame module has, below the window opening, a module carrierwhich forms a blocking layer and bears diverse assemblies. This achievesa limited modularity of the door because the door box only forms thebasic door below the window, but does not achieve a noticeable reductionin weight or a further reduction in costs.

In the case of the door of the “SMART” car known in practice, hinges,the lock, the guides of frameless windows, diverse assemblies andan,interior covering are fitted to an inner supporting frameworkconsisting of light metal profiles. The outer skin is only pushed ontothe supporting framework. Although this construction is light in weight,it cannot be satisfactory with regard to occupant protection forvehicles of normal dimensions. In addition, the outer skin can easily beremoved from the outside, which is an invitation for thieves.

It is the object of the present invention to provide a door constructionwhich considerably surpasses known constructions with regard to safety,protection of the occupants, weight and costs. The reduction in thecosts requires modularization to the greatest possible extent, i.e. thebasic elements of supporting panel, interior covering and outer skinhave to be able to be combined with one another in different variants.

SUMMARY OF THE INVENTION

The foregoing object is achieved by providing a supporting panelconsisting of a reinforced plastic is a solid structural part whichsatisfies all static and dynamic load situations, such as frontalcollision, side collision, quasi-static door indentation, doordepression and door over-compression. It also serves as a support forall of the door assemblies and the door covering. On account of thetight-fitting fastening, it also serves as a separation of wet zone anddry zone, with the window on the outer side of the supporting panelbeing situated in the wet zone. Given appropriate selection of material,the solid supporting panel may also serve as attack-proof armor-plating.

The connection of the edge of the supporting panel in its plane to afirst and a second frame plate can be screwed or riveted and permitstolerance compensation, which facilitates the assembly and improves thefitting precision of the finished door. Since the frame plates arefolded profiles, they can be deformed in the event of a collision andthus compensate for the small deformation distance of the stiffsupporting panel. This effect is further increased by the first,parallel limb of the profile being connected to the edge of thesupporting plate and its second limb being directed transversely to thesurface of the door and being deformed in the case of a collision.

Since the door inside part is a shell consisting of plastic, stiffnessmatching the function is obtained even with a small wall thickness. Theshell is of such a depth that the door inside part protrudes outwardover the supporting panel and forms a connecting flange. In the interiorof the shell, the supporting panel bears completely or at points againstfirst fitting surfaces via the frame plates and bears directly against asecond fitting surface and is fastened there in a tight-fitting mannerin each case. The fastening takes place by means of screws or rivetswhich again also permit tolerance compensation. The solid supportingpanel, which is connected in a tight-fitting manner to the door insidepart consisting of plastic, also provides audibly better muffling ofnoises.

The door outside part is a skin which is fastened in a positive mannerto the connecting flange. Said door outside part can consist of anydesired material (steel, light metal or plastic) because it does notcome into contact with the metallic frame. Thus, electrochemicalreactions cannot occur. The positive connection is only accessible withthe door open, i.e. security against theft is increased. With the dooropen, it can, however, easily be interchanged, which is an advantage in,the case of relatively light damage or for individuals wanting differentcolored doors. The relatively flat shape of the outer skin furthermoreresults in simple production and free selection of the material.

The first frame plate is preferably connected to hinges and the secondframe plate is preferably connected to a door lock. Force is thereforeintroduced from the supporting panel directly to the hinges or to thelock without loading the door inside part.

In a development of the invention, a collision protection support isprovided which is fastened by its ends to the first and second frameplates outside the supporting panel Since it is outside the supportingpanel, it thus has a relatively large deformation distance even beforethe supporting panel comes into effect.

The profile of the first and second frame plates preferably has, atleast in part, a third limb which is approximately parallel to the firstlimb and is outside the latter. This third limb not only stiffens theframe plate and enlarges its capacity for absorbing deformation energy;it is also to be intended that the collision protection support isfastened to it. The fastening to the frame plate again provides directintroduction of force into the lock and hinges with an interactionbetween the supporting panel and collision protection support beingprovided via the frame plate.

A further aspect of the invention comprises the first and second frameplates extending as far as the lower edge of the window opening, and aseparate window frame being placed on the upper edge of the supportingpanel and being fastened to the first limb and to third limb of theprofile. This means, first of all, that the door can be used both withand without window frames (as a frameless window for Cabriolets). Inthis case, the resting on the supporting panel and the adjustableconnection to the frame permits sufficiently stiff fastening and preciseadjustment during assembly. The latter because the first and third limbsof the profile are parallel and at some distance from each other. Thisis a substantial step to complete modularity.

Within the context of the invention, the supporting panel itself candiffer greatly in design. In a particularly suitable design, itcomprises an inner wall and an outer wall consisting of fiber-reinforcedplastic, which walls are connected to each other at least along theedge, and cavities being provided between the walls. They can also beconnected in the meantime by inwardly directed ribs. This producesmaximum stiffness at the lowest weight. The fastening elements thenengage on the common edge. There is thus a solid separating wall betweenthe wet zone and dry zone. No a damage is done if the supporting panelhas an aperture which forms an inner edge and at which the walls areconnected to each other. On the contrary: if the window opener motor isaccommodated in this aperture and is connected in a tight-fitting mannerto the inner edge, its electrics are situated in the dry zone—and, as aresult, conventional plugs are sufficient—and its output is situated inthe wet zone which also contains the window.

In an advantageous development of the invention, the supporting panelhas integrated metallic inserts for fastening means Said inserts can bemolded metal parts, in particular threaded bushings, and can accommodatethe fastening means for the frame plates and also the fastening meansfor diverse, further assemblies, for example the window guides on theside facing the door outside part.

A further step toward producing full modularity comprises the doorinside part having, on its surface facing the vehicle interior, insertsor openings for the attachment of insert parts or covering parts. Saidparts can then be used as desired in various furnishing variants, colorsor qualities. In the extreme case, the openings can be so large that thedoor inside part just forms a frame into which then an entire doorinterior covering complete with loudspeakers etc. can be inserted.

In a preferred development, the door inside part has, on its upper edge,a window seal and plug-in elements with which it is placed, verticallyonto the supporting panel. The door inside part therefore extends as faras the window, is securely fastened and yet can easily be fitted.

In a development, the door inside part has a peripheral rubber sealwhich bears against the supporting panel. In the case of particularlyexacting requirements or in complicated situations, this measure canimprove the sealing of the dry zone and at the same time acts in anoise-isolating manner. There are exacting requirements, for example, ifthe cabling is pre-assembled on the inside of the door inside part andnormal lines and plugs are used and are to last for a long time.

In a development of the invention, provision is made for the dooroutside part to have, on its three edges which are connected to the doorinside part, inwardly folded zones with holes in which the positivefastening means engage through holes in the connecting flange. In thismanner, the connection is not only inaccessible with the door closed,but is also invisible. If it is also to be invisible with the door openand is additionally to be protected from moisture, then a sealing lipcan be provided on the connecting flange on the door inside part, saidsealing lip overlapping the positive fastening means on that side of thedoor inside part which faces away from the door outside part. Finally,the door outside part can have a reinforcement and a window seal on itsupper edge.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described and explained below with reference tofigures, in which:

FIG. 1 shows a schematic outside view of a door according to theinvention,

FIG. 2, sheet A and sheet B, shows an exploded drawing of the door inFIG. 1,

FIG. 3 shows a view of part of the door according to the invention,

FIG. 4 shows a section 4—4 in FIG. 1,

FIG. 5 shows a section 5—5 in FIG. 1,

FIG. 6 shows a section 6—6 in FIG. 1,

FIG. 7 shows a section 7—7 in FIG. 1,

FIG. 8 shows a section 8—8 in FIG. 1,

FIG. 9 shows a section 9—9 in FIG. 1,

FIG. 10 shows a section 10—10 in FIG. 1

DETAILED DESCRIPTION

In FIG. 1, the basic door is denoted by 1 and is also called surface ofthe door in the context of the invention. A window frame 2, which boundsthe window surface 2* upward and laterally is situated above said door.Otherwise, FIG. 1 serves in particular for specifying the position ofthe sections illustrated in FIG. 4 to FIG. 10.

FIG. 2 shows the components of the door according to the inventiondistributed over two sheets (A, B). They are mentioned in the order oftheir assembly. In FIG. 2A, a supporting panel is denoted by 3. Itconsists of reinforced plastic, extends essentially over the surface ofthe basic door 1 and, is designed and dimensioned in such a manner thatit withstands all static and dynamic actions of force. It is connectedfixedly, but releasably, on its vertical, front part of the edge to afirst frame plate 4 and on its rear part of the edge to a second frameplate 5. Hinges 6, 7 and, in between, a door stopper 8 are screwed tothe first frame plate; a door lock 9 is screwed to the second frameplate 5. A window 10 with window opener, window opener motor 11 andwindow guides with fastening bases 12 are screwed to the outer side ofthe supporting panel 3, which can be seen in the FIG. A collisionprotection support 13 is then fitted on that side of the window 10 whichfaces away from the supporting panel 3, and is screwed to the frameplates 4, 5.

The window frame 2 comprises an outer window frame 14, an inner windowframe 15, a window seal 16 and a mirror support 17. These parts areconnected to one another, are placed onto the supporting panel 3 and areconnected to the frame plates 4, 5 in a manner yet to be described.

FIG. 2B illustrates the supporting plate 18 which has been completelyequipped in this manner. It is now inserted into a door inside part 19Sand connected to the latter. The door inside part 19 is of shell-shapeddesign, the edges of the shell protrude outward over the supportingpanel 3 and end in a connecting flange which is denoted in general by 21and to which the door outside part 20 is then fastened from the outside.The tight-fitting connection between supporting panel 3 and door insidepart creates a dry space between the two. The space between thesupporting panel 3 and the door outside part 20 is a wet space. Finally,the outside mirror 22 is also fitted.

FIG. 3 shows a view of the supporting panel 3 from the outside of thevehicle. It comprises an inner wall and an outer wall, consisting offiber-reinforced plastic, which walls are connected to each other atleast along the edge and contain cavities between them. This cannot beseen in FIG. 3 and reference is made in this regard to DE 198 09 750 A1by the same applicant. The supporting panel 3 has a front, vertical edge30, a rear, vertical, edge 31, a lower edge 32 and an upper edge 33. Onthe front edge 30, a support 34 (cross-hatched) for the first frameplate 4 is provided with metallic inserts 35 for fastening it. A supportfor the second frame plate 5 (cross-hatched) and inserts 36 forfastening it are provided on the rear edge 31. Furthermore, a cutout 37can be seen in the rear edge 31, which creates space for the door lock9. On the lower edge 32 are inserts 38 for the connection to the doorinside part 19. Further inserts 39 are for the fastening of the bases ofthe window guide 12. Provided approximately in the center of thesupporting panel 3 is an aperture 40 in which the two walls of thesupporting panel 3 are connected to each other and form an inner edge towhich the window, opener motor 11 is fastened. In this manner, theaperture 40 is sealed by the window opener motor 11, but permits thesupply of power to the latter from the dry space formed on the inside ofthe supporting panel 3.

FIG. 4 shows, in a horizontal section, the connection of the rear edge31 of the supporting panel 3 to the second frame plate 5. Fororientation purposes, the B-pillar 41 is indicated. The cross section ofthe second frame plate 5 consists of a first limb 42, a second limb 43and a third limb 44. The first limb 42 is connected to the supportingpanel 3. This takes place by means of bolts 45 which are screwed intothe inserts 36 in the supporting panel 3. For tolerance compensation,the diameter of the holes 46 in the first limb 42 is larger than thediameter of the bolt 45. The door inside part 19 comprises anessentially planar vehicle-inside wall part 48 which is optionallyperforated (not illustrated), and a shell wall 49 which runs parallel tothe second limb 43 without touching the latter. The third limb 44 isapproximately parallel to the first limb 42 and the collision protectionsupport 13 is fastened to it by means of bolts 47. The tolerancecompensation described with reference to the bolt 45 is also providedhere.

The shell wall 49 of the door inside part 19 protrudes outward over thesupporting panel 3 and the second frame plate 5 and forms a connectingflange 50 to which the door outside part 20 is fastened by means ofpositive fastening means 59, for example is screwed on or clipped on. Sothat this fastening is invisible and inaccessible from the outside ofthe vehicle, the door outside part is folded inward there and isprovided with an insertion plate 51. If the fastening is also to beinvisible and protected even with the door open, a seal 52 having anoverlapping sealing lip 53 is provided.

FIG 5 is a horizontal section level with the upper hinge 6. The profileof the first frame plate 4 again consists of, a first limb 55, a secondlimb 56 and a third limb 57. Again in the manner described withreference to FIG. 4, the supporting panel 3 is fastened to the firstlimb (55) and the hinge 6 to the second limb (56), the shell wall 49 ofthe door inside part 19 being clamped into place here at the same time.The fastening takes place by means of bolts 58, again with the describedtolerance compensation. For orientation purposes, the A-pillar 54together with the door seal (not specifically denoted) is indicated.

FIG. 6 is the horizontal section in the region of the door lock on therear, vertical edge 31 of the door. Owing to the cutout 37 in thesupporting panel 3, the cross section of the second frame plate 5 isextended to this height. The cutout 37 creates space for the door lock 9(merely indicated here) which interacts with a locking pin 60 fastenedto the B-pillar 41. The door lock 9 is screwed to the second frame plate5, it not being possible to see this in the FIG. The second limb 43 ofthe second frame plate 5 is connected at this height to the shell wall49 of the door inside part 19 and the third limb 44 is continued as faras the supporting panel 3. A cutout 61 for the entry of the locking pin60 is provided in the door inside part 19 and in the limbs 42, 43 of theframe plate 5. The shell part 49 forms here a fitting surface 49′ forthe second frame plate 5. A connecting flange 63 for the fastening ofthe door outside part 20 is again provided on the edge of the shell part49. In a departure from FIG. 4, said connecting flange is arrangednormally here sand not parallel to the surface of the door outside part.

FIG. 7 is a horizontal section level with the door stopper 8. It differsfrom that of FIG. 5 by, on account of the door stopper 8, the doorinside part 19 having an opening 70 and the first frames plate 4 havingan inwardly folded part 71 having a punched-out area to which the stop72 for the door stopper 8 is fastened.

FIG. 8 is a vertical section in the zone of the lower edge 32 of thesupporting panel 3 and a door sill 80. The door inside part 19 here hasa sealing rib 82 onto which a rubber seal 81 is placed. The latter canbe provided for better sealing of the dry space and can bear against thesupporting panel 3 along any desired, closed line. The supporting panel3 is screwed to a second fitting surface 83 by means of bolts 84.Sockets 38 are again let into the supporting panel, on its lower edge32. The inside diameter of said sockets can again be larger than thediameter of the bolt 84, for the purpose of tolerance compensationduring assembly.

FIG. 9 is a vertical section through the region of the upper edge 33 ofthe supporting panel 3. The door inside part 19 is bent outward at thetop and forms a horizontal edge zone 90 in which inner plug-in elements91, which are placed onto the upper edge 33 of the supporting panel 3,are provided. Furthermore, an inner window seal 92 is fitted in thehorizontal edge zone 90. An outer window seal 93 is placed onto theupper edge of the door outside part 20 and onto a reinforcement 94connected to the latter. Further downward, this reinforcement 94 canhave two bearing tabs 95 on which an outer door handle 96 is mountedpivotably.

FIG. 10 is a vertical section in the region of the upper edge 33 of thesupporting panel 3 and shows the fastening of the window frame 2 on thedoor. The window frame 2 comprises an outer window frame 14 and an innerwindow frame 15 which are connected to each other and rest on the upperedge 33 of the supporting panel 3 and of the frame plate 5. Its firstlimb 42 and the third limb 44 are parallel to each other and at somedistance from each other. The inner window frame 15 is screwed to thefirst limb by means of a screw 100 (or by a number of screws). The screw100 can at the same time be one of the screw bolts used to connect theframe plate 5 to the supporting panel 3. The outer window frame 14 isscrewed to the third limb 44 of the frame plate 5 by means of bolts 101.For this purpose, vertical slots can be provided in the outer windowframe 14 or in the third limb 44, for adjusting the angle of inclination102 of the window frame 2 with respect to the basic door 1. By thismeans, tolerance compensation is also provided here and a dimensionallyprecise assembly of the door is possible. In the event of a framelesswindow, this section would essentially be identical to the one in FIG.9.

What is claimed is:
 1. Motor vehicle door, comprising a door insidepart, a door outside part and a supporting panel which is connected in atight-fitting manner to the door inside part, wherein a) the supportingpanel, (3) is a structural part consisting of a reinforced plastic,extends essentially over a surface of the door and has an edge (30, 31,32, 33) all the way around, b) a first frame plate (4) and a secondframe plate (5) are connected to the edge of the supporting panel (3),said frame plates being folded profiles which extend along verticalparts of the edge and each having a first limb (42, 55) of which isdirected parallel to the surface of the door (1) and a second limb (43,56) of which is directed transversely to the surface of the door (1),the first limbs (42, 55) being connected to the edge (30, 31) of thesupporting panel (3), c) the door inside part (19) is a shell consistingof plastic with first fitting surfaces (49′) to which the second limbs(43, 56) of the first and second frame plates (4, 5) are fastened, atleast over part of its length, and with a second fitting surface (83) towhich the supporting panel (3) is fastened, and wherein the door insidepart (19) forms shell parts (49) protruding outward over the supportingpanel (3), and a connecting flange (50, 63), d) the door outside part(20) is a skin which is fastened to the connecting flange (50, 63) bymeans of positive fastening means (59).
 2. The motor vehicle door asclaimed in claim 1, wherein the first frame plate (4) is connected tohinges (6, 7) and the second frame plate (5) is connected to a door lock(9).
 3. The motor vehicle door as claimed in claim 1, wherein acollision protection support (13) is fastened by its ends to the firstand second frame plates (4, 5) outside the supporting panel (3).
 4. Themotor vehicle door as claimed in claim 3, wherein the profile of thefirst and second frame plates (4, 5) has, at least in part, a third limb(44, 57) which is approximately parallel to the first limb (42, 55) andis outside the latter.
 5. The motor vehicle door as claimed in claim 4,wherein a collision protection support (13) is fastened to the thirdlimb (44, 57).
 6. The motor vehicle door as claimed in claim 5, whereinthe first and second frame plates (4, 5) extend essentially as far asthe upper edge (33) of the supporting panel (3), and wherein a separatewindow frame (2) is placed on an upper edge (33) of the supporting panel(3) and is fastened to the first limb (42, 55) and to the third limb(45, 57) of the profile.
 7. The motor vehicle door as claimed in claim1, wherein the supporting panel (3) comprises an inner wall and an outerwall consisting of fiber-reinforced plastic, which walls are connectedto each other at least along the edge (30, 31, 32, 33) and cavities areformed between the walls.
 8. The motor vehicle door as claimed in claim7, wherein the supporting panel (3) has an aperture (40) which forms aninner edge and at which its walls are connected to each other.
 9. Themotor vehicle door as claimed in claim 1, wherein the supporting panel(3) has integrated metallic inserts (35, 36, 39) for fastening means(38, 45).
 10. The motor vehicle door as claimed in claim 8, wherein thesupporting panel (3) bears window guides (12) on a side facing the dooroutside part.
 11. The motor vehicle door as claimed in claim 1, whereinthe door inside part (19) has sockets on its surface facing the vehicleinterior, for the attachment of insert parts.
 12. The motor vehicle dooras claimed in claim 1, wherein the door inside part (19) has, in itsupper edge zone(90), a window seal (92) and plug-in elements (91) withwhich it is placed vertically onto the supporting panel (3).
 13. Themotor vehicle door as claimed in claim 1, wherein the door inside part(19) has a peripheral rubber seal (81) which bears against thesupporting panel (3).
 14. The motor vehicle door as claimed in claim 13,wherein cabling is pre-assembled on the inside of the door inside part(19).
 15. The motor vehicle door as claimed in claim 1, wherein the dooroutside part (20) has, on its three edges which are connected to thedoor inside part (19), inwardly folded zones (51) with holes in whichthe positive fastening means (59) engage through holes in the connectingflange (50, 63).
 16. The motor vehicle door as claimed in claim 14,wherein a sealing lip (53) is provided on the connecting flange (50, 63)on the door inside part (19), said sealing lip overlapping the positivefastening means (59) on that side of the door inside part (19) whichfaces away from the door outside part (20).
 17. The motor vehicle dooras claimed in claim 14, wherein the door outside part (20) has areinforcement (94) and an outer window seal (93) on its upper edge.